Fire retarding system for polymeric compositions, and a method and products comprising the same

ABSTRACT

An improved and economical fire retarding system for polymeric compositions comprising the combination of a halogen-containing hydrocarbon and an oxide of iron or an oxide of copper; a method of rendering polymeric compositions resistant to flame; and the flame resistant polymeric compositions and products comprising the same.

0 127% United Stat 1111 3,908,068 MacKenzie, Jr. Sept. 23, 1975 FIRE RETARDING SYSTEM FOR [56] References Cited POLYMERIC COMPOSITIONS, AND A UNITED STATES PATENTS METHOD AND PRODUCTS COMPRISING 2,463,983 3/1949 Leatherman 106/15 FP THE SAME 2,480,298 4 1974 Happoldt, Jr, 260 41 B I 2,610,920 9/1952 Hoplansen 106/15 F1 [75] Invemms' 2 Tgfs g f 3,121,067 2/1964 NBlSOIl 106/ 15 FF 9"? enberg 3,124,557 3/1964 ElCl'lhOl'l'L. 106/15 FP Falrfleld both of 3,154,515 10/1964 Berridge 106/15 FP Assigneez General Electric p y, New 3,202,567 8/1965 MUIl 106/15 FP York, N.Y. Primary Examiner-James H. Derrmgton 1 Flledi p 197,3 Attorney, Agent, or FirmRaymond G. Simkins; [21] AppL NuZ 400,830 Philip L. Schlamp; Frank L. Neuhauser 57] ABSTRACT [52] US. Cl 428/389; 106/15 FP; 174/110 A;

174 10 1.14/1) 260/28 5 An improved and economical fire retarding system for 260/28 2160/28 5 260/4'2 f polymeric compositions comprising the combination 260/42 260/4242 260/42 260/42 of a halogen-containing hydrocarbon and an oxide of 260/42 26O/8'97O 5 iron or an oxide of copper; a method of rendering pol- [51] Int Cl 2 B32B 15/08 C08K 3/22 CO8K 5/02 ymeric compositions resistant to flame; and the flame [58] Fieid 106/l5 260/41 B resistant polymeric compositions and products com- 260/45.75 R, 45.75 P; 117/232 prising thesame' 6 Claims, 1 Drawing Figure FIRE RETARDING SYSTEM FOR POLYMERIC COMPOSITIONS, AND A METHOD AND PRODUCTS COMPRISING THE SAME BACKGROUND OF THE INVENTION Fire retarding systems based upon the combination of halogen-containing materials with antimony compounds such as oxides or halides of antimony have heretofore been extensively utilized to impart resistance to flame and combustion in polymeric compositions and other materials. For example, US. Pat. No. 2,480,298 of Aug. 30, 1949, teaches the use of at least 6 percent by weight of a chlorinated hydrocarbon in combination with to 35 percent by weight of antimony trioxide as a flame proofing agent or system for polyethylene compositions.

The need for obtaining more effective resistance to flame or fire in polymeric products and other materials, moreover, has prompted efforts to improve this basic system of combinations of halogenated materials and antimony compounds such as are disclosed in US. Pat. Nos. 3,582,518; 3,740,245; and 3,741,893. Other recent patents, including U.S. Pat. Nos. 3,340,226 and 3,705,128, have proposed the use of a variety of metal compositions, such for example, as tin and zinc compounds, as substitutes or supplements for antimony compounds in halogen-containing fire retarding systems as a means of enhancing resistance to flame and overcoming shortcomings of the basic system.

SUMMARY OF THE INVENTION The present invention involves the discovery of an improvement in those basic and conventional fire retarding systems which contain a halogen material and an antimony compound, and it comprises the replacement of the antimony compound, or its equivalent metal compound in the system, with a more effective and economical component, namely, an oxide of iron or copper and combinations thereof. Accordingly, this invention includes novel and more effective fire retarding systems composed of new and improved combinations of more economical ingredients and the resultant compositions and the method of obtaining such compositions.

OBJECTS OF THE INvENTIoN It is accordingly an object of this invention to provide a more effective and economical fire retarding system comprising novel combinations of halogen-containing hydrocarbons with low cost metal oxides.

It is another object of this invention to increase resistance to flame and combustion in flame retarded polymeric compositions through the use of an improved fire retarding system of reduced material costs and thereby improve effectiveness while providing a savings in materials.

It is also an object of this invention to provide new and improved polymeric compositions, and products thereof, of improved resistance to flame and combustion and methods for producing the compositions.

It is a further object of this inventionto provide electrical conductors with polymeric insulations of improved resistance to flame and combustion, at lower costs.

BRIEF DESCRIPTION OF THE DRAWING The drawing comprises a perspective view illustrating an insulated conductor product manufactured according to this invention.

DESCRIPTION OF THE PREFERRED EMBODIMENTS This invention comprises the replacement, or supplernentation, of antimony compounds, such as oxides or halides of antimony, or other metal compound equivalents therefor, in fire retarding systems of halogen-containing hydrocarbons, with more effective and lower cost components comprising particulate ferric oxide, cuprous oxide and cupric oxide, or mixtures thereof. The improvements and advantages of this invention are derived from both the discovered superior effectiveness of the oxides of iron or copper in combination with a halogen-containing hydrocarbon as a fire retarding system whereby increased resistance to flame and combustion is attained, and the generally lower costs of oxides of iron or copper as compared with the cost of antimony compounds and many of their equivalents in the prior art.

The enhanced fire retarding systems of this invention include the new combinations of oxides of iron or oxides of copper, and mixtures thereof, with the halogencontaining materials which had heretofore been used in fire retarding system with antimony compounds or their equivalents, including the halogenated hydrocarbons of US. Pat. No. 2,480,298 and the other prior art patents cited above. For example, conventional halogenated hydrocarbons for flame resistance comprise chlorinated parrafin, chlorinated propanes, chlorinated propylenes, hexachloroethane, chlorinated polythene, chlorinated polyisobutylene, polyvinyl chloride, polyvinylidene chloride, after-chlorinated polyvinyl chloride, chlorinated polyphenyls, chlorinated naphthalenes, hexachlorobenzene, chlorinated indenes, chlorinated polystyrenes, chlorinated diphenyl alkanes, and their brominated or other halogenated equivalents. Also included as conventional halogenated hydrocarbons are proprietary halogenated flame retardants such as Hooker Chemical Companys Dechlorane Plus 5 l 5, Diamond Alkali Companys Chlorowax, and similar products.

The proportions of the ingredients of the novel combinations comprising the fire retarding systems of this invention, and also the amounts of the combinations of the system added to polymer compositions can vary considerably and depend primarily upon the degree of resistance to flame or combustion required or desired, and also upon the combustion characteristics of the particular polymeric composition treated. However, with the fire retarding systems of this invention, typical amounts of the oxides of iron or copper for dispersion through a polymeric composition comprise approximately 5 to 10 percent by weight thereof based upon the total weight of the combustible components of the overall polymeric composition. Moreover, inasmuch as the components of this invention are more effective in the fire retarding systems than antimony compounds, the amounts of iron and copper oxides can be reduced from the proportions of antimony previously used to achieve equivalent levels of resistance to flame and fire, or similar amounts of iron or copper oxides to those of former antimony use can be employed with attendant increases in resistance to flame and fire. Genof a given polymeric composition and the level of resiserally, amounts of particulate iron or copper oxides of To provide the halogen-containing material for the from at least about 3 percent up to about 15 percent by fire retarding systems evaluated within the given polyweight, based upon the total weight of the combustible ethylene composition, 20 parts by weight of a commercomponents of the overall polymeric composition, will cial flame retardant, Hooker Chemical Companys Desuffice in most applications and provide the 5 chlorane 602, was combined with the said polyethylene prerequisite level of flame resistance. formulation. Dechlorane 602 is a Diels-Alder conden- The proportions of the halogen-containing material sation reaction product between 1 mole of furan and 2 of the novel combinations of the improved fire retardmoles of hexachlorocyclopentadiene, having a chlorine ing systems of this invention are generally the same as content of 69.4 percent by weight and the structural employed in the prior art systems containing antimony formula of:

compounds. Moreover, as is well known and appreciated in the art, since it is the halogen of this component of the system which provides the resistance to flame and combustion, supplemented or enhanced by the C1 c1 presence of an antimony or other metal component,

the amount of a halogen-containing material utilized depends upon the content or proportion of halogen in 91 such a material and its availability at flame or combustion temperatures as well as the degree of flammability Cl C].

tance to flame and combustion desired or required therefor. Generally, overall halogen contents of within 61 I the approximate range of about 8 to 50 percent by weight thereof based upon the total weight of the combustible ingredients of the polymeric compositions provide effective levels of resistance to flame and combus- The flame resistance of the foregoing polyethylene tion when combined with the metal oxides of this incomposition containing 20 parts by weight of Dechlovention. Frequently about 15 to 35 percent by weight rane 602 as a standard, and also this base composition of overall halogen content will serve most applications. including antimony trioxide, zinc borate, or an oxide of The following examples and data derived from a this invention, and in some cases containing an addicomparative evaluation of several fire retarding systional halogen-containing material, were each meatems and ingredients, including the system of this insured by the Oxygen Index Test (ASTM D-2863-70). vention comprising the replacement of antimony triox- The halogen-containing materials and/or metal comide with smaller proportions of the lower costs oxides, pounds added to the given base composition providing when applied to common crosslink cured polyethylene the standard, and the oxygen index values of the stancompositions with a typical chlorine-containing hydrodard alone and including the added halogen-containing carbon, demonstrate the relative effectiveness of such materials and/or metal compounds in the amounts systems and the advantages and improvements of this specified are all given in the following table of the fire invention. retarding systems and'their relative resistance to flame.

The polymeric composition employed to evaluate the 40 All amounts of ingredients are in relative parts by effects of oxides of iron and copper upon fire retarding weight, and in each instance the base composition is systems with a halogen-containing material, consisted present in 125.5 parts by weight, in the relative proporof the cured product of the following typical curable tions of ingredients set forth above.

EXAMPLES Base Composition (1255) Standard l 2 3 4 5 i 6 7 8 9 Hexabromobiphenyl l0 l0 Decabromobiphenyl 1O Antimony trioxide l0 l0 Ferric oxide(Fe O;,) 6.67 6.67

Iron oxides, Mapico 6.67

Brown 421 lron oxides, Mapico 6.67

Red 381 Cuprous oxide (Cu- O) 6.67

Zinc Borate 10 Oxygen Index Value 0.21 1 0.250 0.234 0.241 0.245 0.259 0.245 0.245 0.236 0.213

" Mapico Brown 421 and Mapico Red 381 are proprietary products of Binney and Smith Company and comprise oxides of iron which are marketed as pigmens and fillers for a variety of products.

The polyethylene compositions of the standard and compound formulation given in relative parts by also including the additives of each examples were all weight: Polyethylene (low density polyethylene, Sinprepared and heat cured with the peroxide curing agent clair Koppers Co.) 100 parts; Antioxidant, polymerin an identical manner. That is all ingredients of the forized l,2-trimethyl-2,2,4 dihydroquinoline (Agerite mulation, except the peroxide curing agent were first Resin D, R. T. Vanderbilt Co.) 1 part; Curing coablended by mixing at a roll temperature of about 200F gent, triallyl cyanurate 1 part; and Peroxide curing for a period of about 10 minutes on a two roll rubber agent, diacumyl peroxide (Di Cup R, Hercules Co.) mill, then the .peroxidecuring agent was added and 3.5 parts. mixing continued at a temperature of 200F for 3 minutes. Equal quantities of the blended composition of the standard and each sample .was molded at about 1,300 psi and 350F for about 45 minutes, thereby crosslink curing the polyethylene with the peroxide agent, and forming a test specimen measuring 4 /2 inch X 4%. inch for evaluation of its flame resistance by the oxygen index test procedure.

The improved, and more economical fire retarding systems comprising oxides of iron or copper of this invention are particularly applicable to polyolefin polymeric materials and compositions, either cured or uncured, comprising ethylene-containing polymers such as polyethylene, copolymers of ethylene and other polymerizable materials, and blends of polymers or copolymers of ethylene with other polymeric materials such as ethylene-vinyl acetate, copolymers of ethylene and propylene and terpolymers of ethylene and propylene with a diene and the like.

The flame retarded polymeric compositions of this invention are suitable for use in the formation of a variety of products and articles wherein resistance to flame is a factor. The compositions provided by this invention are particularly useful as flame resistant dielectric insulations and jackets for wire and cable and other electrical conductors.

A typical flame resistant polymeric insulated electrical conductor product containing the novel combination of ingredients of the improved fire retarding system of this invention is illustrated in the drawing. Referring to the drawing, the flame resisting insulated product comprises a metallic conductor, composed of either a single strand as shown or a bundle of individual strands, having an overlying electrically insulating covering 14 of a polymeric composition containing dispersed therethrough the combination of an oxide of iron or copper with a halogen-containing hydrocarbon.

The method of rendering polymeric materials or compositions thereof resistant to flame and combustion according to this invention, comprises the addition and distribution of the components of the novel fire retarding system comprising a particulate oxide of iron or copper with a halogen-containing hydrocarbon throughout the mass of the polymer by any suitable mixing or compounding technique or apparatus.

The flame retarded composition of this invention may also include other conventional and typical ingredients, additives and agents, depending upon the intended service of the products formed therefrom, and their required or desired properties. For example other components may comprise preservatives, lubricants, mold release agents, pigments or coloring agents, fillers, processing aids, waterproofing agents, coupling agents, and additional flame proofing materials.

Although the invention has been described with ref erence to certain specific embodiments thereof, numerous modifications are possible and it is desired to cover all modifications falling within the spirit and scope of this invention.

What we claim as new and desire to secure by Letters Patent of the United States is:

1. A flame resistant polymeric composition comprising polyethylene including the combination of the condensation reaction product of one mole of furan and two moles of hexachlorocyclopentadiene with at least one particulate metal oxide selected from the group consisting of ferric oxide and ferrous oxide, said condensation reaction product being present in the composition in an amount sufficient to provide about 8 to 6 about 50 percentby weight of chlorine based upon the weight of the organic content of the composition and said metal oxide being present in an amount of about 3 to about 15 percent by weight of the organic content of the composition.

2. An electrical conductor having a flame resistant insulation thereabout, comprising a metallic conductor and an insulating composition comprising a crosslink cured ethylene-containing polymer selected from the group consisting of polyethylene, copolymers of ethylene and other polymerizable materials, and blends of polymers of ethylene with other polymeric materials including the combination of a chlorine-containing hydrocarbon comprising the condensation reaction product between one mole of furan and two moles of hexachlorocyclopentadiene in an amount sufficient to provide about 15 to about 50 percent by weight of chlorine based upon the organic content of the insulating composition, with at least one metal oxide selected from the group consisting of ferric oxide and ferrous oxide in an amount of about 5 to about 15 percent by weight of the organic content of the insulating composition.

3. A flame resistant polymeric composition comprising an ethylene-containing polymer including the combination of the condensation reaction product of one mole of furan and two moles of hexachlorocyclopentadiene with at least one particulate metal oxide selected from the group consisting of ferric oxide and ferrous oxide, said condensation reaction product being present in the composition in an amount sufficient to provide about 8 to about 50 percent-by weight of chlorine based upon the weight of the organic content of the composition and said metal oxide being present in an amount of about 3 to about 15 percent by weight of the organic content of the composition.

4. The flame resistant polymeric composition of claim 3, wherein the ethylene-containing polymer comprises at least one member selected from the group consisting of polyethylene, copolymers of ethylene and other polymerizable materials, and blends of polymers of ethylene with other polymeric materials, and the condensation reaction product is present in the composition in an amount sufficient to provide about 15 to about 50 percent by weight of chlorine based upon the organic content of the composition and the metal oxide is present in the composition in an amount of about 5 to about 15 percent by weight of the organic content of the composition.

5. An electrical conductor having a flame resistant insulation thereabout, comprising a metallic conductor and an insulating composition comprising a crosslink cured polyethylene polymer including the combination of the condensation reaction product of one mole of furan and two moles of hexachlorocyclopentadiene with at least one particular metal oxide selected from the group consisting of ferric oxide and ferrous oxide, said condensation reaction product being present in the composition in an amount sufficient to provide about 8 to about 50 percent by weight of chlorine based upon the weight of the organic content of the insulating composition and said metal oxide being present in an amount of about 3 to about 15 percent by weight of the organic content of the insulating composition.

6. An electrical conductor having a flame resistant insulation thereabout, comprising a metallic conductor and an insulating composition comprising a cross-link cured ethylene-containing polymer including the combination of a chlorine-containing hydrocarbon com- 8 sition, with at least one metal oxide selected from the group consisting of ferric oxide and ferrous oxide in an amount of about 3 to about 15 percent by weight of the organic content of the insulating composition. 

1. A FLAME RESISTANT POLYMERIC COMPOSITION COMPRISING POLYETHYLENE INCLUDING THE COMBINATION OF THE CONDENSATION REACTION PRODUCT OF ONE MOLE OF FURAN AND TWO MOLES OF HEXACHLOROCYCLOPENTADIENE WITH AT LEAST ONE PARTICULATE METAL OXIDE SELECTED FROM THE GROUP CONSISTING OF FERRIC OXIDE AND FERROUS OXIDE, SAID CONDENSATION REACTION PRODUCT BEING PRESENT IN THE COMPOSITION IN AN AMOUNT SUFFICIENT TO PROVIDE ABOUT 8 TO ABOUT 50 PERCENT BY WEIGHT OF CHLORINE BASED UPON THE WEIGHT OF THE ORGANIC CONTENT OF THE COMPOSITION AND SAID METAL OXIDE BEING PRESENT IN AN AMOUNT OF ABOUT 3 TO ABOUT 15 PERCENT BY WEIGHT OF THE ORGANIC CONTENT OF THE COMPOSITION.
 2. An electrical conductor having a flame resistant insulation thereabout, comprising a metallic conductor and an insulating composition comprising a crosslink cured ethylene-containing polymer selected from the group consisting of polyethylene, copolymers of ethylene and other polymerizable materials, and blends of polymers of ethylene with other polymeric materials including the combination of a chlorine-containing hydrocarbon comprising the condensation reaction product between one mole of furan and two moles of hexachlorocyclopentadiene in an amount sufficient to provide about 15 to about 50 percent by weight of chlorine based upon the organic content of the insulating composition, with at least one metal oxide selected from the group consisting of ferric oxide and ferrous oxide in an amount of about 5 to about 15 percent by weight of the organic content of the insulating composition.
 3. A flame resistant polymeric composition comprising an ethylene-containing polymer including the combination of the condensation reaction product of one mole of furan and two moles of hexachlorocyclopentadiene with at least one particulate metal oxide selected from the group consisting of ferric oxide and ferrous oxide, said condensation reaction product being present in the composition in an amount sufficient to provide about 8 to about 50 percent by weight of chlorine based upon the weight of the organic content of the composition and said metal oxide being present in an amount of about 3 to about 15 percent by weight of the organic content of the composition.
 4. The flame resistant polymeric composition of claim 3, wherein the ethylene-containing polymer comprises at least one member selected from the group consisting of polyethylene, copolymers of ethylene and other polymerizable materials, and blends of polymers of ethylene with other polymeric materials, and the condensation reaction product is present in the composition in an amount sufficient to provide about 15 to about 50 percent by weight of chlorine based upon the organic content of the composition and the metal oxide is present in the composition in an amount of about 5 to about 15 percent by weight of the organic content of the composition.
 5. An electrical conductor having a flame resistant insulation thereabout, comprising a metallic conductor and an insulating composition comprising a crosslink cured polyethylene polymer including the combination of the condensation reaction product of one mole of furan and two moles of hexachlorocyclopentadiene with at least one particular metal oxide selected from the group consisting of ferric oxide and ferrous oxide, said condensation reaction product being present in the composition in an amount sufficient to provide about 8 to about 50 percent by weight of chlorine based upon the weight of the organic content of the insulating composition and said metal oxide being present in an amount of About 3 to about 15 percent by weight of the organic content of the insulating composition.
 6. An electrical conductor having a flame resistant insulation thereabout, comprising a metallic conductor and an insulating composition comprising a cross-link cured ethylene-containing polymer including the combination of a chlorine-containing hydrocarbon comprising the condensation reaction product between one mole of furan and two moles of hexachlorocyclopentadiene in an amount sufficient to provide about 8 to about 50 percent by weight of chlorine based upon the weight of the organic content of the insulating composition, with at least one metal oxide selected from the group consisting of ferric oxide and ferrous oxide in an amount of about 3 to about 15 percent by weight of the organic content of the insulating composition. 